Straightening pull-threads in nylon hose



R. D. HUTCHISON STRAIGHTENING PULL-THREADS IN NYLON HOSE Jan. 10, 1950 Filed Jan. 18, 19

2 Sheets-Sheet l JNVENTOR. M93507 9; flurry/s0 ronmans Jar 10, 1950 R. D. HUTCHISON 2,493,876

STRAIGHTENING PULL-THREADS IN NYLON HOSE Filed Jan. l8, 1949 2 Sheets-Sheet 2 INVENTOR.

19705587 0. HUTfH/SON .threads would likewise be adaptable to Patented Jan, 10, 195G ATEQT7OF-FICE STRAIGHTENING PULL-THREADS IN 1 NYLON HOSE Robert D. Hutchison', Croydon, Pa., assignorto Chadbourn Hosiery Mills, Incorporated, a corporation of North Carolina Application January 18, 1949, Serial N0.." 71 ,4 05

13 Glaims. (Cl.661)

' The present invention relates to a system for straightening pull-threads in knitted hosiery, which are accidentally produced. during the manufacture of the hosiery.

This invention has particular application to nylon hosiery, whichiis the most popular form of hosiery at the present time, but it may also be used for straightening pull-threads in other hosiery, e. g. cotton, silk and rayon hosiery. For illustrative purposes, but without limitation thereto, the invention will be described hereafter with respect to nylon hosiery; it being understood that the method and means may be used in similar manner for. other hosiery.

The fact that nylon is a plastic type material and thus may be softened by heat and reset renders it. especially adaptable to the method and means of. this invention, which includesas a final step,.a heating of the straightened pullthread so that it will be reset in itsoriginal length and position. Hosiery knitted of other plastic this method of straighteningv pull-threads.

Nylon'fibers are identified generically as syn thetic linear long chain polyamide fibers. have, at present, largely-replaced all other fibers, such as, for example, silk, rayon and like materials in theprcduction of hosiery. A full de-f They 1 scription as to the chemical identity and char- I acteristics possessed by nylon fibers is givenlin W. H. Carothers Patents .Nos. 2,071,250, 2,071,251 and 2,071,253. Likewise, the employment of these fibers in the production of hosiery is described in PatentNo. 2,157,119 to J. B. Miles and Patent No. 2,157,116 to W. H. Carothers.

Nylon hose are commonly made by knitting on either a circular or flatknitting machine, and the knitting is followed by a'number of oper. ations on the hose, including a pre-boarding operation in which the nylon hose is trained over a metal leg-shaped form and subjected to .a steam treatment to "set the yarn and shape the hose substantially like the contour of the human fish-eye, snake-eye, duck-eye," or eat-eye. Nylon hose possessing a pull-thread or distorted stitch obviously cannot be marketed as first-class hosiery, but must be classified as seconds, or at least a lower -grade,and sold in this form at a reduced price.

Some attempts have been made'heretofore to correct pull-threads by restoring the thread to its original position in the fabric and thereby render the nylon hose suitable for sale as firstclass hosiery. However, nylon fibers possess inherent physical andchemical characteristics which have rendered themethods heretofore attempted of limited utility. Furthermore, the now popular-very sheer nylonhose is particularly susceptible to pull-threads or snags and has made the pull thread problem of substantial commercial importance.

' In accordancewith'my invention, I have provided, for the =firs'ttime, a satisfactory practical 'method'and means for straightening pull-threads and permanently restoring the straightened threads in-nylonlios'e'to'their original or natural position. The method comprises tensioning the area of the hose-containing the pull-thread over a forming cup, stroking the pull-thread in the line of its kinkand away from the hole formed therein with a special type of needle, until the pull-thread is straightened to its normal length, moistening the area; containing the straightened pull-thread, and ironing the moistened area with a special type of iron until the straightened thread is set and permanently restored to its Original position in the hose.

"Regarding thefirst requirement above, of tensioning the defective portion of the hose over the forming cup, the tension should be regulated, through 7 practice, to a degree sufficient to straighten that part of the hose but nevertheless leg. A number of other operations are necessary to produce a finishednylon hose, e. g. lubricate ing, scouring, dyeing finishing, rinsing, etc, The handling of the hose during these various operations results in a substantial number of pull-threads or What is commonly referred to by the consumer asa snag. Actually, a pullthreadis not one which is broken or pulled out of the -h0se,;but rather is one which is kinked .or drawn upand resultsusually in a small hole.

., threadshasaa handle,.a pointedneedle. shaft in the finished hose. This defect is commonly referred to by the operators or inspectors as a united'tothe handle,v anda dull or ball point at the working/end .ofthe needle shaft. The needle shaft,isgadvantageously made of stainless steel orGerman silver, which minimize any tendency to mark theliosef.

For smoothing andsetting the thread after it has been straightened to its original length and position, I have developed a special form of iron comprising a hollow handle, a hollow shaft connected to the handle, a hollow blunt-shaped tip positioned in the forward end of the hollow shaft, insulated, electric current conducting wire extendingthrough said handle, and insulated high resistance wire positioned within said shaft and said tip and having its ends connected to the electric wire, said high resistance wire being designed to limit the heat of the tip below the melting point of the nylon threads. This temperature control is such that the iron will not burn the hose even if left in contact with the hose.

Further features and advantages of the method and means of my invention for straightening pull-threads and restoring the straightened thread in the hose to its original position, will be clearly understood from the detailed description given hereinafter in conjunction with the accompanying drawings in which:

Fig. 1 is a perspective view illustrating the first step of my invention for straightening the pull-thread;

Fig. 1a is a perspective view illustrating the next step of my invention, for moistening the straightened thread;

Fig. 2 is a perspective view of the third step of my invention for smoothing and setting the straightened thread;

Fig. 3 is a plan view of one form of needle suitable for use in my invention;

Fig. 4 is a plan view of another form of needle suitable for use in my invention, in which the needle shaft is detachably threaded to the handle;

Fig. 5 is a longitudinal view partly in section of the needle of Fig. 4;

Fig. 6 is a plan view of a third form of needle suitable for use in my invention, in which the needle shaft is detachably connected to the handle by means of a chuck or pin vice;

Fig. 7 is a longitudinal view partly in section of the needle of Fig. 6;

Fig. 8 is a vertical cross-section of the electrically heated iron suitable for use in the smoothing and setting step of my method; and,

Fig. 9 is a perspective view of a stand or rest holding the iron of Fig. 8.

Referring now to the several figures in the drawings, and at first to Fig. l, for illustration of the first step in my method, it will be observed that the nylon hose I having a pull-thread 2 is positioned, with the above mentioned regulated tension, over the open top of the cup 3. The latter may be of any suitable shape such as, for example, cup-shaped, goblet-shaped, etc., and made from any desired material, e. g. metal, porcelain, plastic, or wood. As herein illustrated, the cup 3 comprises a cylindrical base 4, a stem 5, and a hollow cylindrical body member 6, the body member 6 having a cylindrical lip I over which the nylon hose I will be tensioned.

After the area of the nylon hose I containing the pull-thread 2 has been tensioned over the lip T of the member 3, the operator presses his fingers 8 at the top of the hollow member 3 to maintain the desired tension and retain the hose in a smooth, substantially flat plane. The operator next positions the needle-like member 9 in his fingers Ill and places the dull or'ball-point end l2 of the needle 9 in contact with the pull-thread 2. The angle at which the needle is held with respect to the hose, as illustrated in Fig. 1, is about 4 45, but the needle may be lowered to a greater angle if desired.

The operator then begins a gentle stroking action with the needle 9 in the line of the kink of the pull-thread 2 and away from the center of the hole formed in the hose I by the pull-thread 2. It has been found best to use at first short strokes and gradually increase the length of the stroke until the end of the pull-thread is reached. Usually the operator will stroke first to the right of the hole as shown in Fig. l, and then orient his right hand and stroke to the left of the hole, until the entire length of the pull-thread is straightened, and as a result the hole is gradually minimized in size and finally disappears. The steady stroking action with the ball-point needle 9 will gradually work out the kink of the pullthread 2 and restore the straightened thread to its original length and position.

Following the above described straightening action, the straightened thread and adjacent area of the hose is next moistened, to condition it for the subsequent treatment with the heated iron. This moistening treatment as illustrated in Fig. la is an important step in that it makes possible a final and permanent setting of the straightened thread in the succeeding ironing operation.

As illustrated in Fig. 1a, the operator applies with his finger a small amount of moisture to the affected small area of the hose. This may be done by dipping the finger or fingers I0 in a small bowl of water, or by rubbing them on a wet sponge, and then lightly rubbing the hose so that the drops of water deposit on the threads and produce a moistened area such as illustrated at The straightened and moistened thread, which was the pull-thread, is now ready for the final smoothing and setting operation with the heated iron, as illustrated in Fig. 2. The operator holds the iron by the handle 2I and applies the blunt tip l5 to the moistened area I 3 and begins a gentle, steady stroking action in the line of the straightened thread. The heated tip 15 effects a further straightening and softening of the pullthread 2, evaporates the moisture in the area I3, and causes the thread 2 to become set in its restored length. It will be understood from the above description that the three steps of straightening, moistening, and smoothing and setting, may be carried out without removing the hose from the forming cup, and that the three operations may be carried out in close succession. Fol lowing the last step the hose is removed from the forming cup and is ready for final inspection and packing,

I have ascertained from actual experiences that the above described steps of my novel method for straightening pull-threads and ermanently restoring the straightened threads to their original location may be eificiently carried out with the special instruments illustrated in Figs. 3 through 9 of the drawing. Referring at first to Fig. 3, a needle suitable for use in the first step of my method comprises a hexagonal-shaped handle I6 having its lower portion conically shaped, a needle member 9 having one end pressfitted within the conically shaped portion of said handle, and a ball-shaped point I2 integrally formed at the opposite end of the member 9. This rounded point I2 is important to prevent damage to the hose. It may be formed originally and reshaped as often as necessary by bufling on a felt roll and using jewelers rouge. The handle 16 may be made of any suitable material such as,

.snca-ev's safely housedwithin the handle ll.

Another modified form oi-ne'edle, as illustrate inFigs. 6 and '7,is of similar constructionto the needle shown in Figs; land 5. In this second modification the vinstrumentcomprises a hollow handle H, anda chuck 'or'pin-vicearrangement illustrated at l9a'rid'2llf0rholding'the needle 9, which is of the samestructure and material as hereinbeforedescribed, and is positioned within the handle llwhen notin use. The advantages of these two modified forms of needle are that the points or the needle may be completely protectedirom any harm when -not in use. This is important in order to ensure'that the ball-point l2 of the needle twill retain itsdesired rounded shape.

An iron-which I have developed for use in my method as described above, is illustrated in Fig. 8 of the drawings. It comprises a handle member 2! having a hollow shaft 22 extending therethrough. A tubular member 23 is secured to one end of the handle 2-! by a collar 24. The outer end of the member 23 is bent to form an angled lower shank portion 25. This bent portion 25 is of particular utility in that it permits the operator to iron in a flat level plane. Positioned within the lower shank portion 25 is a metal heating tip I5 preferably made of a chrome alloy steel and about five-sixteenth inches in diameter and one inch in length. The tip l5 may be positioned within the lower shank'portion 25 by'any suitable means, such as a simple press fit. Extending through the hollow bore 22 of the handle 2i is a conventional electrical lead line 21 havingan outlet plug28 for connection to an ordinary 110- volt power source.

Insulated and spiral wound high resistance wire 29 is positioned within the hollow shank-23 and the tip l5. This resistance Wire has its ends 35 connected acros the electricalleadlines 2'1. This high resistance wire 29 is commercially available and is covered with an asbestos insulation 3 I. The wire is centrally positioned within the hollow shank 23 in a manner so as to avoid any substantial contact of the wire with the Side walls of the shank 23. This construction provides an air space insulation which keeps the shank 23 from becoming too hot. The insulated high resistance wire 29, however, comes into direct contact with the inner walls of the heating tip l5 to provide a quick and even heat. The length of the wire 29 and the dimensions of the tip l5 are so adjusted that the temperature of the tip will not exceed approximately 235 F. Otherwise, the iron would cause a melting of the nylon fibers.

Additionally, it should be noted that the heated tip 25 possesses a substantially blunt or flat cylindrical point in order to use the instrument for its intended purpose. If an instrument possessing an angled tip such as that found in a soldering iron were employed in my method, it would be difficult to iron out and set the straightened thread.

Another feature of my iron is. the collar 33 which is secured to the electrical lead 21. This collar is 'adapted toabut against theshoulder at formed within the hollow portion 22 0f the'handle 2! 'By this construction it will be'readily observedthat the Wire can never-be pulled out from the handle duet'o the collar 33 strikingagainst the shoulder 34.

Beferringnow-to Fig.9, there is shown a small stand 35 adapted to provide a handy support or rest for the heating iron l4 when not in use. The support 35 comprises abase 36 of any suitable size and an upright hollow shaft 37 mounted on said base 3%. Positioned within the hollow portion 3'! at its upper end is a supportingmember 38 which has its upper ends split to form a Y-shaped support 39in which the shank portion 23 of the heating iron may beplaced. This-stand may be formed of wood, plastic, metal or other suitable material. By this construction I provide astand orsupport which permits the operator to'hav'e ready access to the heating-iron and likewise maintain the heated tip out of contact.

I claim:

l. The method of straightening pull-threads in hosiery knitted of thermoplastic threads and permanently restoring the straightened .threads to their original position, which comprises tensioning the area containing the pull-thread over a supporting member, stroking said I pull-thread with a needle in the direction of said pull-thread sufiiciently to straighten the pull-thread-and restore the straightened thread to its normal-length and position, moistening said restored'threadand applying a heated iron to said moistened'thread to maintain the thread permanently in its straightened position.

2. The method of straightening pull-threads in nylon hose and permanently restoring the straightened threads to their original position,- which comprises tensioning the area containing the pull-thread over a supporting member; stroking said pull-thread with'a needle in the-direction of said pull-thread'sufiiciently to straighten the pull-thread and restore the straightened thread to its normal lengthand position, moistening said restored thread-and applying a heated iron to said moistened thread to set the nylon thread permanently in its straightened position.

'3. The method of straighening a pull-thread in nylon hose and permanently restoring the straightened thread to its original length and position, comprising stroking the pull-thread with a rounded point needle until the pull-thread is straightenedmoistening the straightened thread, and heating the thread at a temperature suincient to set the nylon thread without damaging the hose.

4. A method as defined in claim 3 and in which the needle during stroking is positioned at an angle of at least 45 with respect to the hose.

5. A method as defined in claim 3 and in which the pull-thread is stroked in the direction of the length of the pull-thread and at first with short strokes and then with progressively longer strokes to the outer end of the pull thread.

6. An electrically heated blunt pointed iron for use in smooothing and setting previously straightened pull-threads occurring in hosiery, comprising a hollow handle, a hollow metal shank connected to one end of said handle, a blunt hollow cylindrical heating tip positioned within said shank, electrical leads extending through said hollow handle, high resistance insulated wire positioned within said shank and said tip and having its ends connected across said electrical leads, said tip and said high resistance wire being of 7 Such character as to heat said tip no higher than about 235 F.

7. An electrically heated blunt pointed iron for use in smoothing and setting previously straightened pull-threads occurring in nylon hosiery, comprising a hollow handle, a hollow metal shank connected to one end of said handle, said metal shank having its outer and bent to form substantially a right angle thereto, a blunt hollow cylindrical heating tip positioned within said shank, electrical leads extending through said hollow handle, high resistance insulated wire positioned within said shank and said tip and having its ends connected across said electrical leads, said tip and said high resistance wire being of such character as to heat said tip no higher than about 235 F.

8. An electrically heated blunt pointed iron for use in smoothing and setting previously straightened pull-threads occurring in nylon hosiery, comprising a hollow handle, a hollow metal shank connected to one end of said handle and having its lower end bent to form substantially a right angle thereto, a blunt hollow chrome alloy steel heating tip positioned within said shank, electrical leads extending through said hollow handle, high resistance insulated wire positioned within said shank and said tip, said high resistance wire being free from contact with the side walls of said shank and being in close contact with the side walls of said tip, said high resistance wire having its ends connected across said electrical leads, and said tip and said high resistance Wire being of such character as to heat said tip no higher than about 235 F.

9. An electrically heated blunt pointed iron adapted for use in smoothing and setting previously straightened pull-threads occurring in nylon hosiery comprising a hollow handle, a shoulder recess positioned within said handle, a hollow metal shank connected to one end of said handle, a blunt hollow cylindrical heating tip positioned within said shank, electrical leads extending through said hollow handle, a flanged collar secured to said wire and adapted to abut against said shoulder, high resistance insulated wire positioned within said shank and said tip and having its ends connected across said electrical leads, and said tip and said high resistance wire being of such character as to heat said tip to their original position, which comprises tensioning the area of the hosiery containing the pull-thread, stroking the pull-thread in the direction of the pull until the pull-thread is restored to its normal length and positioned, moistening said restored thread and applying heat to said moistened thread to maintain the thread permanently in its straightened position.

11. The method of straightening a pull-thread in nylon hose and permanently restoring the straightened thread to its original length and position, comprising stroking the pull-thread in the direction of the pull until the pull-thread is restored to its normal length and position, moistening the restored thread, and heating the moistened thread at a temperature suflicient to set the nylon thread without damaging the hose.

12. In the method of straightening pull-threads in nylon hose, the step of stroking the pull-thread in the direction of the pull with a pointed instrument until the pull-thread is restored to its normal length and position.

13. An electrically heated blunt pointed iron for use in smoothing and setting previously straightened pull-threads occurring in nylon hosiery, comprising a hollow handle, a hollow metal shank connected to one end of said handle, electrical leads extending through said hollow handle, high resistance insulated Wire positioned within said shank and having its ends connected across said electrical leads, and means positioned in the extending end of said shank and adjacent said high resistance insulated wire for heating the blunt end of the iron no higher than about 235 F.

ROBERT D. HUTCHISON.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,792,121 Pieper Feb. 10, 1931 2,093,631 Burnham Sept. 21, 1937 2,157,119 Miles May 9, 1939 2,213,797 Claussner Sept. 3, 1940 2,214,084 Lovice Sept. 10, 1940 2,288,464 Kitchener June 30, 1942 2,365,467 Hammerstein Dec. 19, 1944 2,448,032 Kennedy Aug. 31, 1948 OTHER REFERENCES Hu-Friedy Mfg. Co. Catalog Nov. 13, 1923. 

